Plasma-enhanced High-speed Arc Spraying of Fe-based Coatings：Effect of Spraying Power on Coating Organization, Tribological Properties, and Corrosion Resistance

doi:10.3901/JME.2025.10.066

Abstract

Abstract: In the service process of offshore equipment, key components are subjected to a complex environment characterized by corrosion-wear interactions over extended periods. This exposure results in significant surface damage, compromising the safety and reliability of equipment operation. Treating the surface of the workpiece to achieve a robust thermal spray coating is an effective solution to this issue. In this study, iron-based coatings were successfully prepared using plasma-enhanced high-speed arc technology (PE-HAS). The impact of spraying power on the microstructure, mechanical properties, and wear and corrosion resistance of the coatings was thoroughly investigated. The results indicate that the primary physical phase composition of the coating consists of austenite and martensite. When the spraying power is either insufficient or excessive, the structure of the coating deteriorates, leading to a decline in its tribological and corrosion resistance properties. Optimizing the spraying current to 500 A results in an excellent microstructural configuration, thereby enhancing the mechanical properties, tribological performance, and corrosion resistance of the coating. In conclusion, controlling the spray power during PE-HAS is crucial for wire melting, which significantly influences the densification of the coating's microstructure.

Key words: PE-HAS, spraying power, organizational structure, mechanical properties, tribological properties, corrosion resistance

CLC Number:

TG178

GAO Rui, LIU Ming, FAN Wei, HUANG Yanfei, JIN Guo, ZHANG Hanbing, MA Guozheng, WANG Haidou. Plasma-enhanced High-speed Arc Spraying of Fe-based Coatings：Effect of Spraying Power on Coating Organization, Tribological Properties, and Corrosion Resistance[J]. Journal of Mechanical Engineering, 2025, 61(10): 66-74.

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